Repair Procedure
Repair ProcedureRemove the Fuel Tank
NOTE:
The fuel tank removal process described is generic to all models. For details about the model you are working on, refer to the FUEL SUPPLY section under Group 13 - FUEL of the applicable service manual for the specific model.
1. If the fuel tank is more than 1/4 full, remove as much fuel as possible, storing it in clean containers approved for gasoline storage. You will return this fuel to the vehicle when repairs are complete.
2. Reduce fuel pressure (refer to Group 13A - FUEL, On Vehicle Service).
3. Remove the rear seat cushions and gain access to the service hole(s) by removing the cover(s).
a. For Endeavor, the carpet is partially cut at the service hole locations. Use a knife to complete the cuts to gain access to the service holes.
4. Disconnect the fuel pump electrical connector
5. Disconnect the fuel tank differential pressure sensor.
6. Disconnect both of the fuel level sending unit connectors (main and sub).
CAUTION:
Take steps to prevent the vehicle from rolling during step 7.
7. For Endeavor AWD, turn the ignition key to the "ON" position, place the shift lever in 'N' (Neutral) and release the parking brake. Turn the key to the ACC. position, turn off all accessories (fans, radio, etc.).
8. Raise the vehicle.
9. Remove the center exhaust pipe.
10. For Endeavor AWD only, perform the following steps:
a. Remove the propeller shaft from the differential.
b. Remove the nuts securing the rear propeller shaft support bearing.
c. Place the propeller shaft as far to one side as possible and secure it to the lift assembly using a strap.
11. Remove the parking brake cable clamps.
12. Disconnect the fuel tank vapor hoses.
13. Disconnect the fuel filler hose.
14. Disconnect the high pressure fuel hose.
15. Remove the fuel tank support straps.
16. Using a transmission jack as support, carefully lower the fuel tank out from under the vehicle.
Equipment
The parts and equipment shown above are required to complete the Reinforcement Cap Installation.
Reinforcement Cap Installation
CAUTION:
There are several operations in the Reinforcement Cap Installation procedure where safety glasses should be worn.
READ THROUGH THE FOLLOWING PROCEDURE PRIOR TO INSTALLING THE REINFORCEMENT CAP.
1. Clean the stud and left rear support bracket of residual spray lubricant using non-chlorinated brake cleaner.
2. Using the Scotch-brite(R) pad included in the repair kit, scuff the entire surface of the left fuel tank support bracket to remove paint overspray just until the green primer (e-coat) is dull.
!! IMPORTANT !!
Take care to prevent exposing the bare metal of the bracket.
3. Using the Scotch-brite(R) pad included in the repair kit, scuff the entire surface on the INSIDE of the reinforcement cap to provide a good adhesion surface.
!!CAUTION!!
WEAR SAFETY GLASSES
NOTE:
If the bracket has a crack with a gap greater than 0.3 mm (0.012") use a long drift to tap the surface of the bracket upwards until the gap is closed. The lower surface of the bracket MUST remain flat.
CAUTION:
Do not distort the bracket.
!!CAUTION!!
WEAR SAFETY GLASSES
4. Place the reinforcement cap from the repair kit over the bracket's stud and secure it in position using the tank strap nut.
5. Using the hole in the cap as a guide, drill a 3/16" hole perpendicular (90° angle) to the surface of the bracket through the bracket only. Refer to the photo for the angle of drilling.
!!! CAUTION !!!
DO NOT drill through the floor pan. Drill through the bracket only.
6. Remove the nut and remove the cap.
7. Wipe both scuffed surfaces, inside the cap and outside the bracket, with isopropyl alcohol to clean them. This will ensure good adhesion.
NOTE:
The applicator is packaged with 2 plungers. Use the 1:1 plunger. Discard the 2:1 plunger.
8. Assemble the applicator gun using the plunger marked as 1:1 (both shafts of the plunger are equal diameter). Do not cut the end of the tube.
9. Have the rivet and rivet tool ready for prompt setting of the supplied rivet.
!!! IMPORTANT !!!!
ADHESIVE WORKING TIME IS LESS THAN 4 MINUTES!
10. Refer to the Parts Information section of this bulletin and check the date code of the adhesive being used. DO NOT USE OUTDATED ADHESIVE.
11. Load the adhesive (3M DP805) into the applicator gun and attach the mixing tube from the kit to the adhesive container per the 3M instructions. Do not cut the end of the tube.
12. Apply 2 beads of adhesive to the inside surface of the reinforcement cap exactly as shown in the illustration.
^ The bead along the inside top edge of the reinforcement cap starts at a point 30 mm from the open end of the reinforcement cap on one side and ends at the same point on the opposite side.
^ The second bead is shorter and is positioned below the top bead. It starts 22.5 mm from the beginning of the top bead and ends at the same point on the opposite side of the reinforcement cap.
13. IMMEDIATELY place the reinforcement cap onto the bracket. Do not allow adhesive to get on the stud.
14. IMMEDIATELY place the rivet through the hole in the cap and bracket to avoid the adhesive hardening in the hole. Do not set it at this time. While pressing the cap towards the rear of the vehicle, torque the nut to hold the cap in position during the rivet installation and to maintain cap alignment during initial adhesive curing. Torque to 26 - 31 Nm (19 - 22 ft-lbs).
!!CAUTION!!
WEAR SAFETY GLASSES
15. Using the rivet tool, set the rivet.
16. Remove the mixing tube from the adhesive container and discard it. Replace the cap on the unused portion of the adhesive and store in a cool location (60°F/15°C).
!!! IMPORTANT !!!
Do not remove the nut at this time. The adhesive must have 30 minutes to cure initially before the nut is removed. Reinstall the fuel tank while the adhesive sets. Securing the strap with this nut will be the last step in that process.
Fuel Tank Installation
NOTE:
The fuel tank installation process described is generic to all models. For details about the model you are working on, refer to the FUEL SUPPLY section under Group 13 - FUEL of the applicable service manual for the specific model.
1. Place the front of the fuel tank straps over their respective studs and start the nuts.
2. Slide the fuel tank back into position and attach the rear of the right fuel tank strap over its stud. Leave the rear of the left tank strap loose at this time. Support the tank with a transmission jack.
3. For Endeavor - Torque the 3 tank strap nuts to 26 - 31 Nm (19 - 22 ft-lbs).
For all other models - Torque the right tank strap nut and the nuts holding the front of the tank to the cross member to 26 - 31 Nm (19 - 22 ft-lbs).
4. Reattach the high pressure fuel hose, the fuel filler hose, and the fuel tank vapor hoses.
5. Reposition the parking brake cables and reattach the cable clamps.
6. For Endeavor AWD, install the propeller shaft and the center exhaust pipe.
7. Remove the nut from the reinforced bracket, attach the fuel tank strap over the stud and torque the nut to 26 - 31 Nm (19 - 22 ft-lbs).
8. Lower the vehicle, place the transmission selector in P (park) and remove the key from the ignition.
9. Reattach the connectors to the fuel tank differential pressure sensor, the fuel level sending units, and the fuel pump.
10. Return the fuel removed at the start of the repair procedure to the vehicle's fuel tank.
11. Start the vehicle and check for fuel leaks from the hose connections.
12. Reinstall the covers over the service holes in the interior floor and reinstall the rear seat cushions.
!! IMPORTANT !!
Ensure that the seatbelt buckles are accessible and positioned correctly prior to securing the seat.
INSPECTION
Using the MUT-III, perform an EVAP leak test to ensure integrity of the fuel hose connections. The system must pass this test prior to the vehicle being returned to the customer.
1. Check that the fuel cap is securely closed (tighten until three clicks are heard).
2. Connect the MUT-III to the data link connector.
3. Turn the ignition switch to the "ON" position.
4. From the MUT-III Main Menu, click on "System Select."
5. For 2006 and later vehicles, input the applicable VIN information for your vehicle.
For 2005 and earlier vehicles, continue to step 6.
6. Select "MFI" from the System List.
7. For 2005 models, select Mitsubishi.
For 2006 and later models, continue to step 8.
8. Select "Diagnostic Trouble Code." Record any DTCs. Address them at the end of the procedure.
9. Select "Erase DTCs." This clears all completed monitors and allows the the Evap Leak Test to run.
10. Return to the MFI Menu.
For 2006 and later models, select Special Function.
For 2005 models, select Emissions Test.
11. Start the engine. The A/C should be OFF. Allow the engine to warm up to operating temperature.
12. Select "Evap Leak Mon."
13. During this test, keep the accelerator pedal at the idle position.
14. When the monitor test starts, the "In Progress" item on MUT-III will change from "NO" to "YES."
15. When the evap leak monitor test is complete, turn the ignition switch to the "LOCK" (OFF) position, and disconnect the MUT-III.
16. Address any DTCs that set using the applicable service manual diagnostic procedures. Check all hose connections and conduct further diagnosis on those DTCs that may have been noted in step 8 above.